Ink jet printer system for printing an image on a web overlaying a removable substrate and method of assembling the printer system

ABSTRACT

Ink jet printer system for printing an image on a web overlaying a removable substrate and method of assembling the printer. The ink jet printer system comprises an ink jet print head for jetting ink onto the web to form an image on the web. A feeder mechanism is coupled to the print head for feeding the web and substrate past the print head during printing. A first roller is aligned with the feeder mechanism and is adapted to engage the substrate for removing the substrate from the web. A second roller is aligned with the first roller, the second roller being adapted to layer a covering onto the printed image as the first roller removes the substrate from the web. A third roller is aligned with the second roller for supplying the covering to the second roller. In this manner, a layered web is defined. Moreover, a steaming core is provided to bundle-up the layered web, so that a steaming roll is defined thereby. A steam generator receives the steaming roll and generates steam for fixing the ink to the layered web that belongs to the steaming roll. The covering is removed from the layered web to define a bare web. Further, a washer is disposed to wash the bare web for removing unfixed ink from the bare web. Also, a hot-air blower directs heated air onto the bare web for drying the bare web. A take-up reel may also be provided to engage the bare web and wrap the bare web thereabout for packaging the bare web for shipment.

BACKGROUND OF THE INVENTION

The present invention generally relates to ink jet printer apparatus andmethods therefor and more particularly relates to an ink jet printersystem for printing an image on a web overlaying a removable substrate,and method of assembling the printer system.

It is known to print colorful images on woven and unwoven textiles orfabrics such as cotton, wool, silk, synthetics, and the like prior tothe fabrics being cut and sewn. Of course, the fabrics are cut and sewnto provide articles for everyday use, such as clothing, towels,upholstery and other articles.

Various printing techniques are used to produce the images that appearon the fabric. One technique is to use the well-known process of screenprinting, wherein a screen serving as a stencil and having apredetermined mesh count is coated with ink of a desired color. It isthe back of the screen that is coated with ink. The article to be screenprinted is then placed on the front of the screen and a squeegee bladeis pressed against the back of the screen to work the ink into thearticle. In this manner, the image is printed onto the article.

However, use of screen printing has several disadvantages. For example,screen printing is unsuitable for quickly changing images to be printedin order to keep-up with changes in consumer taste. Also, time requiredto set-up or construct a particular screen stencil and mix the desiredink color in order to print particular image makes screen printing notcost-effective for small quantity production runs. In other words,screen printing is not cost-effective for a large number of smallproduction runs because of the increased frequency of screen set-ups.

Another well-known technique for printing images on fabrics is use of aplate roller having the image engraved on the plate in reverse relief Inthis regard, ink of a desired color is applied to the plate and theplate is then rolled against the fabric to be printed in order to formthe image on the fabric. However, use of the plate roller technique isrelatively expensive because the plate roller technique typically uses arotogravure printing process, which requires fabrication of an intaglioplate prepared by photographic methods. Of course, an intaglio plate isan engraving etched deeply into a surface of a hard material, which istypically metal. Also, time required to engrave the plate in order toprint a particular image makes plate roller printing not cost-effectivefor small quantity production runs. In other words, plate rollerprinting is not cost-effective for smaller production runs because eacharticle is printed from one engraving of the plate and smallerproduction runs would increase frequency of engraving and productionset-ups.

Therefore, the commercial fabric printing industry is shifting fromscreen printing and plate roller printing of fabrics to ink jet printingof fabrics. Ink jet printing of fabrics offers several advantages overscreen printing and plate roller printing. That is, ink jet printingallows immediate changes in color and design of an image in order torapidly adjust to consumer tastes. This is so because ink channelsformed in the ink jet print head can be selectively enabled depending onthe particular image to be printed at that moment. In other words, inkjet printing is well-suited to small production runs as well as largeproduction runs because ink jet printing does not require time-consumingand expensive fabrication and deployment of a screen stencil or anengraved plate every time the design of the image is changed.

However, although not all ink jet printers require fabrics to bestiffened, it has been observed that fabric to be printed by an ink jetprinter typically needs stiffening in order to properly feed through theprinter's feeding mechanism. This is so because the fabric is inherentlyquite flexible in both the longitudinal and transverse directions. Thisinherent flexibility of the fabric may result in misalignment of thefabric or even “jamming” of the fabric in the printer as the fabricfeeds through the printer. Misalignment of the fabric produces images ofinconsistent quality and “jamming” of fabric in the printer causes theprinter to cease operation, at least until the “jammed” fabric iscleared. Therefore, a common practice in the art of ink jet printing offabrics is to provide a substrate, such as a relatively stiff paperbacking material, coupled to the fabric. This backing material may beadhered to the fabric by a suitable adhesive. The backing material isselected for its thickness and stiffness, such that the fabric withbacking material has sufficient stiffness in the longitudinal andtransverse directions to properly feed through the printer.

However, this solution to the previously mentioned “stiffness” problemin turn gives rise to another problem in the art. That is, it ispreferable to remove the relatively stiff backing material from thefabric prior to the fabric being cut and sewn. In the prior art, removalof the backing material is accomplished manually. That is, typically anattendant assigned to operate the printer manually grasps the fabric andbacking material after printing and then peels the backing material fromthe fabric. The backing material is discarded by the attendant. Hence,time and labor are expended to remove the backing material. Therefore,it is desirable to avoid manual removal of the backing material in orderto save time and labor.

Apparatus and methods for ink jet printing of textiles having aremovable backing layer are known. Such an apparatus and method aredisclosed by U.S. Pat. No. 6,071,368 titled “Method And Apparatus ForApplying A Stable Printed Image Onto A Fabric Substrate” issued Jun. 6,2000 in the name of Melissa D. Boyd, et al. and assigned to the assigneeof the present invention. The Boyd, et al. patent discloses an inktransfer sheet including a backing layer, a detachable release layer onthe backing layer, and an ink receiving layer on the release layer.According to the Boyd, et al. patent, the backing layer provides supportfor the other layers while the release layer is used to adhere the inkreceiving layer and printed image onto a fabric substrate. The inkreceiving layer is formulated to allow adhesion and/or absorption of inkmaterials thereon so that a defined printed image can be effectivelytransferred. In this regard, once the ink composition is delivered tothe ink receiving layer of the transfer sheet, the transfer sheet isplaced on and against the selected fabric substrate so that the inkreceiving layer and the printed image are in physical contact with thesubstrate. Heat is applied to the transfer sheet to cause the releaselayer and ink receiving layer to adhere to the fabric substrate. Afteror during application of heat, the backing layer is removed (e.g., byphysical detachment or “peeling”) from the ink transfer sheet. Therelease layer and receiving layer are left on the fabric substrate sothat the printed image is transferred to the fabric substrate. However,although the Boyd, et al. patent discloses removing the backing layerfrom the fabric substrate, the Boyd, et al. patent does not disclosestructure to accomplish this result and therefore does not disclose asolution to the problem of manual removal of the backing layer.

Another ink jet printing apparatus and method for fabric printing aredisclosed by U.S. Pat. No. 6,254,231 B1 titled “Ink-Jet Textile PrintingInk And Ink-Jet Printing Process And Instrument Making Use Of The Same”issued Jul. 3, 2001 in the name of Mariko Suzuki, et al. The Suzuki, etal. patent discloses an ink-jet printing process that includes the stepsof applying an ink to a cloth in accordance with an inkjet system,subjecting the cloth to a reactive fixing treatment, and then washingthe cloth thus treated to remove unreacted dye. However, the Suzuki, etal. patent does not disclose that the fabric has a backing material andtherefore does not disclose a solution to the problem of manuallyremoving the backing material.

Hence, a problem in the art is the practice of manual removal of thebacking material from fabric printed by an ink jet printer.

Therefore, what is needed is an ink jet printer system for printing animage on a web overlaying a removable substrate, and method ofassembling the printer system, the printer system being capable ofremoving the substrate from the web.

SUMMARY OF THE INVENTION

The present invention generally resides in an ink jet printer system forprinting an image on a web overlaying a removable substrate, comprising:a print head for jetting ink onto the web; a feeder mechanism associatedwith the print head for feeding the web and substrate past the printhead; and a first work station associated with the feeder mechanism forremoving the substrate.

According to an aspect of the present invention, the ink jet printersystem comprises an ink jet print head for jetting ink onto the web toform an image on the web. Coupled to the web is a substrate. A feedermechanism is coupled to the print head for feeding the web and substratepast the print head during printing. A first roller is aligned with thefeeder mechanism and is adapted to engage the substrate for mechanicallyremoving the substrate from the web. A second roller is aligned with thefirst roller, the second roller being adapted to layer a covering ontothe printed image as the first roller removes the substrate from theweb. The web with layered covering defines a layered web. The coveringis provided to protect the printed image from damage during subsequenthandling and to prevent “bleed through” of the image, as discussedpresently. In addition, a third roller is aligned with the second rollerfor supplying the covering to the second roller. Moreover, a steamingcore is provided to bundle-up the layered web, so that a steaming rollis defined thereby. A steam generator receives the steaming roll andgenerates steam for fixing the ink to the layered web. The previouslymentioned covering separates successive layers of the web when bundledin the form of the steaming roll. In this manner, ink from the topsurface of the web in one layer of the steaming roll will not contactthe bottom surface of the web in an adjacent layer of the steaming roll.Further, the covering is removed from the layered web and a washer ispreferably disposed to then wash the web for removing unfixed ink fromthe web. Also, a hot-air blower directs heated air onto the web fordrying the web. A take-up reel may also be provided to engage the weband wrap the web thereabout in order to package the web for shipment.

A feature of the present invention is the provision of a first rolleraligned with the feeder mechanism and adapted to engage the substratefor mechanically removing the substrate from the web.

An advantage of the present invention is that use thereof decreasestotal printing time, labor and expense.

Another advantage of the present invention is that use thereof decreaseslikelihood of damage to the web, which in turn decreases wastage.

These and other features and advantages of the present invention willbecome apparent to those skilled in the art upon a reading of thefollowing detailed description when taken in conjunction with thedrawings wherein there are shown and described illustrative embodimentsof the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing-outand distinctly claiming the subject matter of the present invention, itis believed the invention will be better understood from the followingdescription when taken in conjunction with the accompanying drawingswherein:

FIG. 1 is a view in elevation of an ink jet printer system according tothe present invention with parts removed for clarity, the printer systembeing capable of printing an image on a web material, such as fabric;

FIG. 2 is a plan view of the printer system;

FIG. 3 is a view in perspective of an ink jet print head printing theimage on the web in raster-like fashion.

FIG. 4 is a fragmentation view in partial elevation of the ink jet printhead jetting an ink drop onto the web, which web has a substrate coupledthereto;

FIG. 5 is a view in partial elevation taken along section line 5—5 ofFIG. 4;

FIG. 6A is a fragmentation view in elevation of a first embodimentroller removing the substrate from the web; and

FIG. 6B is a fragmentation view in elevation of a second embodimentroller removing the substrate from the web.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention will be directed in particular to elements formingpart of, or cooperating more directly with, apparatus in accordance withthe present invention. It is to be understood that elements notspecifically shown or described may take various forms well known tothose skilled in the art.

Therefore, referring to FIGS. 1, 2, 3 and 4, there is shown an ink jetprinter system, generally referred to as 10, for printing an image 15 ona web 20 overlaying a removable substrate 30. By way of example only andnot by way of limitation, web 20 may be a textile or fabric such ascotton, wool, silk or synthetic textile material. However, although thedescription herein is with reference to web 20 being a textile orfabric, it will be appreciated that web 20 may be any suitable materialthat overlays a removable substrate and upon which image 15 is to beformed. Moreover, substrate 30 is selected so that it is sufficientlystrong and stiff in order that web 20 moves effortlessly through printersystem 10 in a manner disclosed more fully hereinbelow. In this regard,substrate 30 may have a thickness of about 0.04 to 0.16 mm and be madeof any suitable material such as paper, polyester, cellophane, nylon, orother material.

Referring to FIGS. 1, 2, 3, 4 and 5, substrate 30 with web 20 overlaidthereon is presented to a print head 40 in the form of a roll 50 woundabout a rotatable spindle 60. The spindle 60 may be rotated by means ofa first motor 65. Prior to start of printing, an end portion of web 20and substrate 30 are positioned adjacent to print head 40 by anyconvenient means well known in the art, such as manually or bymechanical means (not shown). Moreover, print head 40 itself ispreferably a thermal ink jet print head having a plurality of alignedink channels 70 a, 70 b and 70 c formed therein (only three of which areshown). Of course, it may be appreciated that print head 40 may be apiezoelectric print head. Each channel 70 a, 70 b and 70 c terminates ina channel orifice 7 2 a, 72 b and 72 c, respectively. In addition, eachink channel 70 a, 70 b and 70 c preferably contains a differentlycolored ink 75 a, 75 b and 75 c, respectively, consisting of a dye orpigment dispersion. In this regard, inks 75 a, 75 b and 75 c may possessa red, blue and yellow color, respectively, if desired.

Referring again to FIGS. 1, 2, 3, 4 and 5, during printing, web 20 andsubstrate 30 are supported and fed past print head 40 by a feedermechanism. For example, the feeder mechanism may be a generallycylindrical platen 80 preferably rotatable on an axle 85 and positionedopposite orifices 72 a, 72 b and 72 c. Axle 85 may be rotated by meansof a second motor 87. In addition, a tensioner, such as a capstan roller89, may be provided to engage web 20 and substrate 30 for tensioning web20 and substrate 30. Tensioning web 20 and substrate 30 in this fashionreduces risk of fouling (i.e., “jamming”) of web 20 and substrate 30between print head 40 and platen 80. During operation of thermal ink jetprint head 40, a multiplicity of ink drops 90 (only one of which isshown) are selectively jetted from orifices 72 a, 72 b and 72 c and ontoweb 20 in order to form image 15. Ink drops 90 are preferably jettedonto web 20 by selective explosive formation of a vapor bubble (notshown) in channels 70 a, 70 b and/or 70 c to selectively jet ink drops90 from channels 70 a, 70 b and/or 70 c. As well-known in the art, thevapor bubble is formed due to application of an electrical pulse to aplurality of resistors in respective fluid communication with each ofinks 75 a, 75 b and 75 c. The principal of operation of such a thermalink jet print head is disclosed more fully in U.S. Pat. No. 4,490,728titled “Thermal Ink Jet Printer” issued Dec. 25, 1984 in the name ofJohn L. Vaught, et al. and assigned to the assignee of the presentinvention, the disclosure of which is hereby incorporated by reference.

As best seen in FIG. 3, print head 40 may threadably engage a belt drive100 rotatable by means of a third motor 110. As belt drive 100 rotates,print head 40 will traverse web 20 while channels 70 a, 70 b and/or 70 cselectively jet ink drops 90 onto web 20. Of course, platen 80 isrotated to advance web 20 each time print head 40 traverses web 20 andjets ink drops 90 onto web 20. In this manner image 15 is formed on web20 in a raster-like fashion. Although belt drive 100 is shown forenabling print head 40 to traverse web 20, other motive means may beused, such a screw-drive mechanism (not shown).

Alternatively, print head 40 may be a piezoelectric print head ratherthan a thermal ink jet print head, if desired. In this regard, such apiezoelectric print head also includes channels 70 a/b/c terminating inchannel orifices 72 a/b/c, respectively. However, in this instance,print head 40 is made of a piezoelectric material and ink is selectivelyjetted from orifices 72 a/b/c by means of an electric pulse selectivelyapplied to the piezoelectric material comprising each channel 70 a/b/c.Due to the inherent nature of piezoelectric material, walls of selectedones of channels 70 a/b/c inwardly move when the walls are electricallystimulated. As the walls of the selected channels respond to theelectric stimulus by inwardly moving, ink drops 90 are jetted from theircorresponding orifices. A representative piezoelectric print head isdisclosed in U.S. Pat. No. 6,193,343 titled “Driving Method Of An InkJet Printhead” issued Feb. 27, 2001 in the name of Norigoe, et al.

As previously mentioned, it is important to remove (i.e., peel) therelatively stiff substrate 30 from web 20. This is important in order toprepare the fabric material of web 20 for cutting and sewing. In theprior art, removal of the substrate 30 (i.e., backing material) isaccomplished manually. That is, typically an attendant assigned tooperate printer system 10 manually grasps web 20 (e.g., fabric) andsubstrate 30 (i.e., backing material) after printing and then peelssubstrate 30 from the entirety of web 20. However, this technique ofremoving substrate 30 results in increased total printing time, laborand expense. Moreover, this technique of removing substrate 30 increaseslikelihood of damage to fabric web 20, which in turn increases wastage.Consequently, it is desirable to avoid manual removal of substrate 30 inorder to save time, labor and expense and to avoid damage to fabric web20.

Therefore, referring to FIGS. 1, 2 and 6A, aligned with platen 80 is afirst work station, such as a generally cylindrical and rotatable firstroller 120, for mechanically removing (i.e., peeling) substrate 30 fromweb 20. First roller 120 may be coupled to a fourth motor 130 forrotating first roller 120. The attendant assigned to operate printersystem 10 threads web 20 and substrate 30 from platen 80 by anyconvenient means such as manually or mechanically. The attendant thenseparates a diminimus portion of substrate 30 from web 20 and wraps thatportion of substrate 30 at least partially around first roller 120. Forexample, the attendant may wrap that portion of substrate 30approximately one to one and one half times around first roller 120, ifdesired. That is, the attendant need only peel and wrap a sufficientamount of substrate 30 around first roller 120 so that substrate 30avoids slipping on first roller 120 as first roller rotates by means offourth motor 130. In this manner, as first roller 120 is caused torotate, first roller 120 will mechanically peel the remainder ofsubstrate 30 from web 20 after web 20 and substrate 30 feed past printhead 40.

Referring again to FIGS. 1, 2 and 6A, aligned with first roller 120 is asecond work station, such as a generally cylindrical and rotatablesecond roller 140. As described more fully hereinbelow, second roller140 is adapted to layer a covering 145 onto web 20 as second roller 140rotates and as first roller 120 peels substrate 30 from web 20. Secondroller 140 may be coupled to a fifth motor 150 for rotating secondroller 140. The attendant assigned to operate printer system 10 threadsthe portion of web 20, from which substrate has been separated, intoengagement or contact with second roller 140, as shown. The attendantmay thread that portion of web 20 into engagement with second roller 140by any convenient means, such as manually or mechanically.

Turning now to FIG. 6B, there is shown a second embodiment first roller155. Second embodiment first roller 155 is substantially similar tofirst embodiment first roller 120, except that second embodiment firstroller 155 includes an elongate knife edge or blade 157 having a sharpedge portion 159. The sharp edge portion 159 is capable of engaging theinterface between web 20 and substrate 30 for easing separation of web20 from substrate 30.

Returning to FIGS. 1, 2 and 6A, aligned with second roller 140 is athird work station, such as a generally cylindrical and rotatable thirdroller 160 having a supply of the covering 145 wound thereabout. Thepurpose of third roller 160 is to supply covering 145 to second roller140 as third roller 160 rotates, such as by operation of a sixth motor170. In this regard, the attendant grasps a free end of covering 145 andthreads the free end of covering 145 into engagement or contact withsecond roller 140 such that covering 145 is interposed between web 20and second roller 140. In this manner, covering 145 is caused to layerweb 20 as web 20 and covering 145 engage second roller 140. Thusly, web20 with covering 145 layered thereon defines a layered web 175. Thepurpose of covering 145 is to cover printed image 15, so that image 15is not damaged during subsequent handling and to prevent “bleed through”of the ink forming image 15. That is, covering 145 separates successivelayers of web 20 when web 20 and covering 145 are bundled-up (rolled-up)into a “steaming roll” prior to steaming. In this manner, ink from thetop surface of web 20 in one layer of the steaming roll will not contactthe bottom surface of the web in an adjacent layer of the steaming roll.Covering 145 may be paper or plastic.

Referring to FIGS. 1 and 2, aligned with second roller 140 is a bundlingstation, such as a solid and generally cylindrical steaming core 180,which supports a flexible mesh material, such as a cylindrical wire mesh185 having a relatively low mesh count. Mesh 185 defines openings (notshown) to allow steam therethrough, for reasons disclosed presently. Theattendant threads layered web 175 into engagement with mesh 185 andwraps a portion of layered web 175 about mesh 185. The attendant maywrap the portion of layered web 175 about one and one half turns aroundmesh 185, so that layered web 175 avoids slipping on mesh 185 assteaming core 180 is rotated. As steaming core 180 is rotated, such asby a seventh motor 190, layered web 175 will further wrap around mesh185. Thus, it may be appreciated from the description hereinabove thatmesh 185 is adapted to engage and bundle-up layered web 175, so that asteaming roll 200 is defined thereby.

Referring again to FIGS. 1 and 2, a controller 205 is electricallyconnected to first motor 65, second motor 87, third motor 110, fourthmotor 130, fifth motor 150, sixth motor 170 and seventh motor 190 forsynchronous rotation of motors 65/87/110/130/150/170/190. Controller 205may be any suitable controller, such as is available from AmeriMex Motor& Controls, Incorporated located in Houston, Tex. (USA). Alternatively,only seventh motor 190 may be provided, if desired, and the other motorseliminated for reducing costs. In this case, seventh motor 190 will havebeen selected so as to possess sufficient torque to pull web 20,substrate 30 and covering 145.

Still referring to FIGS. 1 and 2, a fixing station, such as a steamgenerator 210, is disposed to sealingly receive steaming roll 200therein. In this regard, steam generator 210 is adapted to generate anddeliver, such as through a plurality of steam nozzles 215, superheatedsteam permeating steaming roll 200 and its associated web 20 for fixingthe ink to web 20. The superheated steam may have a temperature ofapproximately 100° C. to 110° C. and steaming roll 200 may reside insteam generator 210 a predetermined time depending on the web materialand composition of ink. Steam generator 210 itself has a cover 220rotatable about a hinge 225 for opening and closing steam generator 210,so that steaming roll 200 may be received into and extricated from steamgenerator 210.

Referring yet again to FIGS. 1 and 2, steaming roll 200 is removed fromsteam generator 210 by any convenient means such as manually ormechanically. Layered web 175 is then preferably unwound from steamingroll 200. As layered web 175 is unwound from steaming roll 200, covering145 is removed from layered web 175, such as by means of a de-coveringstation or fourth roller 227 rotatable by a seventh motor (not shown).In this regard, the attendant peels a diminimus portion of covering 145away from layered web 175 and wraps that portion of covering 145 aroundfourth roller 227. The attendant then directs the bare web 20 through awashing station 230 that washes unfixed ink from bare web 20. Thus, itmay be understood from the description hereinabove, that removal ofcovering 145 from layered web 175 is accomplished in a mannersubstantially similar to removal of substrate 30 from web 20. In otherwords, covering 145 is preferably removed from layered web 175 prior towashing, thereby defining bare web 20. Moreover, a drying station, suchas a hot-air blower generally referred to as 240, is disposed to directa column of heated air onto bare web 20 for drying bare web 20 afterbare web 20 is washed. Blower 240 may comprise an air pump 250 forblowing air across a resistance heater 260 in order to supply the heatedair to bare web 20. Alternatively, bare web 20 may be left to naturallyair-dry. In addition, a packaging station, such as a take-up reel 270,is aligned with washer 230 and is adapted to engage bare web 20 forwrapping bare web 20 around take-up reel 270. In this manner, layeredweb 175 is packaged for shipment to a suitable facility for cutting andsewing into articles for everyday use, such as clothing, towels,upholstery and other articles.

It may be understood from the description hereinabove that an advantageof the present invention is that use thereof decreases total printingtime, labor and expense. This is so because substrate 30 is mechanically(i.e., automatically) removed from web 20 rather than being manuallyremoved from web 20 and also because layered web 175 is formedautomatically.

It may be further understood from the description hereinabove, thatanother advantage of the present invention is that use thereof decreaseslikelihood of damage to web 20, which in turn decreases wastage. This isso because manual manipulation of web 20 and substrate 30, along withthe associated human error, is reduced.

While the invention has been described with particular reference to itspreferred embodiments, it will be understood by those skilled in the artthat various changes may be made and equivalents may be substituted forelements of the preferred embodiments without departing from theinvention. For example, a radiant heater may be substituted for hot-airblower 240.

Therefore, what is provided is an ink jet printer system for printing animage on a web overlaying a removable substrate, and method ofassembling the printer system, the printer system being capable ofremoving the substrate from the web.

PARTS LIST

10 . . . ink jet printer system

15 . . . image

20 . . . web

30 . . . substrate

40 . . . print head

50 . . . roll

60 . . . spindle

65 . . . first motor

70 a/b/c . . . ink channels

72 a/b/c . . . ink channel orifices

75 a/b/c . . . ink in channels

80 . . . platen

85 . . . axle

87 . . . second motor

89 . . . capstan roller

90 . . . ink drop

100 . . . lead screw

110 . . . third motor

120 . . . first embodiment of first roller

130 . . . fourth roller

140 . . . second roller

145 . . . covering

150 . . . fifth motor

155 . . . second embodiment of first roller

157 . . . blade

159 . . . sharp edge portion

160 . . . third roller

170 . . . sixth motor

175 . . . layered web

180 . . . steaming core

185 . . . wire mesh

190 . . . seventh motor

200 . . . steaming roll

205 . . . controller

210 . . . steam generator

215 . . . steam nozzles

220 . . . cover

225 . . . hinge

227 . . . fourth roller

230 . . . washer

240 . . . hot-air blower

250 . . . air pump

260 . . . resistance heater

270 . . . take-up reel

What is claimed is:
 1. An ink jet printer system for printing an imageon a web overlaying a removable substrate, comprising: a. a print headfor jetting ink onto the web; b. a feeder mechanism associated with saidprint head for feeding the web and substrate past said print head; andc. a first work station associated with said feeder mechanism forremoving the substrate.
 2. The system of claim 1, further comprising: a.a second work station associated with said first work station, saidsecond work station being adapted to layer a covering onto the web todefine a layered web; and b. a third work station associated with saidsecond work station for supplying the covering to said second workstation.
 3. The system of claim 2, further comprising a bundling stationassociated with said second work station, said bundling station beingadapted to bundle-up the layered web.
 4. The system of claim 3, furthercomprising a fixing station associated with said bundling station forfixing the ink to the web.
 5. The system of claim 4, further comprisinga de-covering station associated with said fixing station for removingthe covering from the layered web.
 6. The system of claim 5, furthercomprising a washing station associated with said fixing station forwashing the web after removal of the covering from the layered web. 7.The system of claim 6, further comprising a drying station associatedwith said washing station for drying the web after washing of the web.8. The system of claim 6, further comprising a packaging stationassociated with said fixing station, said packaging station beingadapted to engage the web for packaging the web after drying of the web.9. The system of claim 1, further comprising a blade associated withsaid first work station for removing the substrate.
 10. An ink jetprinter system for printing an image on a web overlaying a removablesubstrate, comprising: a. an ink jet print head for jetting ink onto theweb to form the image on the web; b. a feeder mechanism coupled to saidprint head for feeding the web and substrate past said print head; andc. a first roller aligned with said feeder mechanism, said first rollerbeing adapted to engage the substrate for removing the substrate fromthe web as the web and substrate are fed past said print head.
 11. Thesystem of claim 10 further comprising: a. a second roller aligned withsaid first roller, said second roller being adapted to layer a coveringonto the web to define a layered web as said first roller removes thesubstrate from the web; and b. a third roller aligned with said secondroller for supplying the covering to said second roller.
 12. The systemof claim 11, further comprising a steaming core aligned with said secondroller, said steaming core being adapted to engage and bundle-up thelayered web therearound, so that a steaming roll is defined thereby. 13.The system of claim 12, further comprising a steam generator disposed toreceive the steaming roll and generate steam contacting the web forfixing the ink to the web.
 14. The system of claim 13, furthercomprising a fourth roller aligned with said steam generator and adaptedto engage the covering for removing the covering from the layered web.15. The system of claim 14, further comprising a washer disposed to washthe web for removing unfixed ink from the web after removal of thecovering from the layered web.
 16. The system of claim 15, furthercomprising a hot-air blower disposed to direct hot air onto the web fordrying the web after washing of the web.
 17. The system of claim 15,further comprising a take-up reel aligned with said washer, said take-upreel being adapted to engage the web and wrap the web thereabout forpackaging the web on said take-up reel after drying of the web.
 18. Thesystem of claim 10, further comprising a blade coupled to said firstroller for removing the substrate.
 19. An ink jet printer system forprinting an image on a web overlaying a removable substrate, comprising:a. an ink jet print head having a plurality of ink jetting orifices forselectively jetting ink onto the web to form the image on the web; b. afeeder mechanism coupled to said print head, said feeder mechanism beingadapted to engage the web and substrate for feeding the web andsubstrate past said print head as said print head prints the image; andc. a cylindrical rotatable first roller aligned with said feedermechanism for peeling the substrate from the web, said first rollerbeing adapted to engage the substrate, peal the substrate from the weband wrap the substrate around said first roller as said first rollerrotates and as the web and substrate are fed past said print head. 20.The system of claim 19, further comprising: a. a cylindrical rotatablesecond roller aligned with said first roller, said second roller beingadapted to layer a covering onto the web to define a layered web as saidsecond roller rotates and as said first roller peals the substrate fromthe web; and b. a cylindrical rotatable third roller aligned with saidsecond roller, said third roller having the covering wound thereabout,said third roller being adapted to supply the covering to said secondroller as said third roller rotates.
 21. The system of claim 20, furthercomprising a cylindrical rotatable steaming core aligned with saidsecond roller, said steaming core being adapted to engage and bundle-upthe layered web therearound as said steaming core rotates, so that asteaming roll is defined thereby.
 22. The system of clam 21, furthercomprising a steam generator disposed to receive the steaming roll andgenerate superheated steam permeating the layered web for fixing the inkto the layered web.
 23. The system of claim 21, further comprising afourth roller aligned with said steam generator and adapted to engagethe covering for removing the covering from the layered web.
 24. Thesystem of claim 23, further comprising a washer disposed to wash the webfor washing-away unfixed ink from the web after removal of the coveringfrom the layered web.
 25. The system of claim 24, further comprising ahot-air blower disposed to dry the web after washing of the web.
 26. Thesystem of claim 22, further comprising a cylindrical rotatable take-upreel aligned with said washer, said take-up reel being adapted to engagethe web and wrap the web thereabout as said take-up reel rotates forpackaging the web on said take-up reel after drying of the web.
 27. Thesystem of claim 19, further comprising a blade associated with saidfirst roller for removing the substrate.
 28. A method of assembling anink jet printer system for printing an image on a web overlaying aremovable substrate, comprising the steps of: a. providing a print headfor jetting ink onto the web; b. coupling a feeder mechanism to theprint head for feeding the web and substrate past the print head; and c.coupling a first work station to the feeder mechanism for removing thesubstrate.
 29. The method of claim 28, further comprising the steps of:a. coupling a second work station to the first work station, the secondwork station being adapted to layer a covering onto the web to define alayered web; and b. coupling a third work station to the second workstation for supplying the covering to the second work station.
 30. Themethod of claim 29, further comprising the step of coupling a bundlingstation to the second work station, the bundling station being adaptedto bundle-up the layered web.
 31. The method of claim 30, furthercomprising the step of coupling a fixing station to the bundling stationfor fixing the ink to the web.
 32. The method of claim 31, furthercomprising the step of coupling a de-covering station to the fixingstation for removing the covering from the layered web.
 33. The methodof claim 32, further comprising the step of coupling a washing stationto the fixing station for washing the web after removal of the coveringfrom the layered web.
 34. The method of claim 33, further comprising thestep of coupling a drying station to the washing station for drying theweb after washing of the web.
 35. The method of claim 30, furthercomprising the step of coupling a packaging station to the fixingstation, the packaging station being adapted to engage the web forpackaging the web after drying of the web.
 36. The method of claim 28,further comprising the step of coupling a blade to the first workstation for removing the substrate.
 37. A method of assembling an inkjet printer system for printing an image on a web overlaying a removablesubstrate, comprising the steps of: a. providing an ink jet print headfor jetting ink onto the web to form the image on the web; b. coupling afeeder mechanism to the print head for feeding the web and substratepast the print heat; and c. aligning a first roller with the feedermechanism, the first roller being adapted to engage the substrate forremoving the substrate from the web as the web and substrate are fedpast the print head.
 38. The method of claim 37, further comprising thesteps of a. aligning a second roller with the first roller, the secondroller being adapted to layer a covering onto the web to define alayered web as the first roller removes the substrate from the web; andb. aligning a third roller with the second roller for supplying thecovering to the second roller.
 39. The method of claim 38, furthercomprising the step of aligning a steaming core with the second roller,the steaming core being adapted to engage and bundle-up the layered webtherearound, so that a steaming roll is defined thereby.
 40. The methodof claim 39, further comprising the step of disposing a steam generatorso as to receive the steaming roll and generate steam contacting the webfor fixing the ink to the web.
 41. The method of claim 40, furthercomprising the step of aligning a fourth roller with the steamgenerator, the fourth roller adapted to engage the covering so as toremove the covering from the layered web.
 42. The method of claim 41,further comprising the step of disposing a washer so as to wash the webfor removing unfixed ink from the web after removal of the covering fromthe layered web.
 43. The method of claim 42, further comprising the stepof disposing a hot-air blower so as to direct hot air onto the web fordrying the web after washing of the web.
 44. The method of claim 43,further comprising the step of aligning a take-up reel with the washer,the take-up reel being adapted to engage the web and wrap the webthereabout for packaging the web on the take-up reel after drying of theweb.
 45. The method of claim 37, further comprising the step of couplinga blade to the first roller for removing the substrate.
 46. A method ofassembling an ink jet printer system for printing an image on a weboverlaying a removable substrate, comprising the steps of: a. providingan ink jet print head having a plurality of ink jetting orifices forselectively jetting ink onto the web to form the image on the web; b.coupling a feeder mechanism to the print head, the feeder mechanismbeing adapted to engage the web and substrate for feeding the web andsubstrate past the print head as the print head prints the image; and c.aligning a cylindrical rotatable first roller with the feeder mechanismfor peeling the substrate from the web, the first roller being adaptedto engage the substrate, peal the substrate from the web and wrap thesubstrate around the first roller as the first roller rotates and as theweb and substrate are fed past the print head.
 47. The method of claim46, further comprising the steps of: a. aligning a cylindrical rotatablesecond roller with the first roller, the second roller being adapted tolayer a covering onto the web as the second roller rotates and as thefirst roller peals the substrate from the web; and b. aligning acylindrical rotatable third roller with the second roller, the thirdroller having the covering wound thereabout, the third roller beingadapted to supply the covering to the second roller as the third rollerrotates.
 48. The method of claim 47, further comprising the step ofaligning a cylindrical rotatable steaming core with the second roller,the steaming core being adapted to engage and bundle-up the layered webtherearound as the steaming core rotates, so that a steaming roll isdefined thereby.
 49. The method of clam 48, further comprising the stepof disposing a steam generator so as to receive the steaming roll andgenerate superheated steam permeating the web for fixing the ink to theweb.
 50. The method of claim 49, further comprising the step ofdisposing a cylindrical rotatable fourth roller, the fourth rolleradapted to engage the covering so as to remove the covering from thelayered web.
 51. The method of claim 50, further comprising the step ofdisposing a washer so as to wash the web for washing-away unfixed inkfrom the web after removal of the covering from the layered web.
 52. Themethod of claim 51, further comprising the step of disposing a hot-airblower so as direct hot air onto the web to dry the web after washing ofthe web.
 53. The method of claim 52, further comprising step of aligninga cylindrical rotatable take-up reel with the washer, the take-up reelbeing adapted to engage the web and wrap the web thereabout as thetake-up reel rotates for packaging the web on the take-up reel afterdrying of the web. 54.The method of claim 46, further comprising thestep of coupling a blade to the first roller for removing the substrate.